Method of installing modular wall construction

ABSTRACT

An interior modular wall for finished or existing rooms in which each module has a panel with an integral floor rail carrying a shorter floor gripper plate which projects from the floor rail and is longitudinally slidably interlocked therewith. The module is installed quickly and simply by manually lifting the module into the vertical plane of a prepositioned longitudinally extending ceiling rail, longitudinally spacing the vertically extending side edge of the module from the corresponding edge of the adjacent module or abutment, lowering the module while in that vertical plane onto the floor so that the gripper plate engages and grips the floor covering, and moving the panel and floor rail unit longitudinally relative to the ceiling rail, floor, and gripper plate into engagement with the adjacent preinstalled module. Both side edges of the panel are free to be gripped by the installer during the lifting and lowering operations, thereby greatly simplifying and reducing the time for erecting the wall.

United States Patent T191 Papsco [5 METHOD OF INSTALLING MODULAR WALLCONSTRUCTION Inventor: William G. Papsco, P10. Box 666,

San Carlos, Calif. 94070 Filed: June 8, 1971 Appl. No.: 151,053

Related U.S. Applieation Data 1969, abandoned.

[52] US. Cl....l .L 52/745, 52/241 [51] Int. Cl E04b 2/82 [58] Field ofSearch 52/745, 741, 241, 52/122, 127, 29, 242, 143, 464, 281, 468;49/453-455 [56] lieferences Cited UN1TED STATES PATENTS 3,189,135 6/1965Slowinski 52/241 3,335,532 8/1967 Greenbie t 52/143 X 3,408,781 11/1968P0110Ck 52/745 X 3,423,892 1/1969 Rimington 52/241 3,570,683 3/1971Dickgiesser 52/143 X Continuation-impart of Ser. No. 820,561, April 30,

, 11] 3,753,328 [451 Aug. 21, 1973 Primary Examiner Price C. Faw, Jr.Attorney.lohn F. Lawler ABSTRACT An interior modular wall for finishedor existing rooms in which each module has a panel with an integralfloor rail carrying a shorter floor gripper plate which projects fromthe floor rail and is longitudinally slidably interlocked therewith. Themodule is installed quickly and simply by manually lifting the moduleinto the vertical plane of a prepositioned longitudinally extendingceiling rail, longitudinally spacing the vertically extending side edgeof. the module from the corresponding edge of the adjacent module orabutment, lowering the module while in that vertical plane Onto thefloor so that the gripper plate engages and grips the floor covering,and

moving the panel and floor rail unit longitudinally relative to theceiling rail,floor, and gripper plate into engagement with the adjacentpreinstalled module. Both side edges of the panel are free to be grippedby the installer during the lifting and lowering operations, therebygreatly simplifying and reducing the time for erecting the wall.

1 Claim, 9 Drawing Figures METHOD OF INSTALLING MODULAR WALLCONSTRUCTION BACKGROUND OF THE INVENTION with which appurtenances, suchas shelves,-work tops and the like may be supported on the structure.With the increasing use of carpets and fabric coverings-for floors,provision must be made for removably attaching such walls to thecarpetingwithoutripping or otherwise damaging it. In addition, the wallsshouldaccommodate uneveness'in the flower ceiling without-unduemodification of the prefabricated panels. Moreover, structuralsimplicity is needed in 'such wall construction so as to permitfabrication of low cost units that provide an economically equivalentalternative to permanent-or semi-permanent wall structures.

These criteria are achievable with a prefabricated wall modulecomprisinga base or floor rail and floor gripper plate integrated with--,the panel as unitary assembly. There is difficulty, vhowever, inmanipulating such a moduleinto final position in the vertical plane ofthe wall and in :end-to-end abutment with the installed adjacentpaneldue to the availability'of onlyone free edge of the panel to bemanually gripped by the workman in the final assembly stage. Jacks .orspecial panel gripping fixtures might be employed to finally positionthe module but this complicates the installation procedure, requiresadditional tools and tends to slow down the entire process.Alternatively, two or more workmen may be used to manipulate the panelswith attendant increases in installation costs.

SUMMARY OF THE INVENTION An object of the invention is the provision ofa modular wall construction with an integrated panel and floor grippermodule that facilitates rapid wall erection without special tools andwithrelatively unskilled workmen.

Another object is the provision of a method ofreadily installing modulesin a modular wall using one workman.

A more specific object is the provision of a simplified method oferecting a modular wall with end-to-end integrated modules wherein bothside edges of the module are gripped by a workman as it moved into theplane of the wall. I

These and other objects are achieved with'an integrated panel, base railand floor gripper plate module in which the gripper plate is shorterthan the base rail and is longitudinally slidably interlocked to theunderside of that raiLJSuch a module construction permits a workman toset each module in the plane of thewall while longitudinally spaced fromthe adjacent module and while the gripper plate frictionally engages thefloor covering. Thereafter the panel and floor rail subassembly aremoved longitudinally into abutment with the adjacent module or side wallwhile the gripper plate remains anchored to the floor and interlockedwith the floor rail.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation of a wallembodying this invention and installed in a carpeted room;

FIG. 2 is a section taken on line 2-2 of FIG. 1;

FIG. 3 is a section similar to the lower part of FIG.

2 illustrating a gripper plate for hard floors;

FIG. 4 is a longitudinal section taken on line 44 of FIG. 2 showing therelative positions of the gripper plate and base rail when a module isplaced in the plane of'the wall in an intermediate position spaced fromthe adjacent module;

. FIG. 5 is a view similar to FIG. 4 showing the relative positions ofthe gripper plate and base rail when the just installed module isin itsfinal position in abutment with the adjacent module;

FIG. 6 is a longitudinal horizontal section of a part of a modified formof a modular wall embodying this invention; and

FIGS. 7, 8 and 9 are schematic elevational views of the modular wall invarious stages of its construction.

DESCRIPTION OF PREFERRED EMBODIMENTS Referring now to FIG. 1 of thedrawings, a wall 10 embodying the invention comprises'a channel-shapedtop or ceiling rail 11 secured by screws 12 to ceiling R of the room anda plurality of substantially identical modules '13 and an end module 14resting on a carpet C on floor'F in vertical alignment with the ceilingrail. Side walls S, and S define the opposite ends'of the modular wall.

Each module comprises a rigid generally rectangular panel 16, achannel-shaped floor rail 17 secured to the bottom edge of the panel,and a carpet gripper plate 18 slidably interlocked with the underside offloor rail 17 and frictionally engaging carpet C under the weight of themodule. Panel 16 is a moderately lightweight laminarstructure comprisinga honeycomb center layer 20 see FIG. 2, cemented to outer layers 21 and22 of porous composition board on tackboard. A suitable fabric ordecorative finish may be applied to the exterior of the compositionboards which preferably have a density suitable to receive and holdthumb tacks and similar fastening means.

Floor rail l7 has side walls 24 and 25 and a bottom wall 26 joined bybeveled or inclined interior surfaces 27 and 28. Side walls 24 and 25are formed with inwardly extending rounded ribs 29 spaced slightly belowthe upper edge of these side walls and tend to snugly engage the sidesof the panels to prevent any lateral play thereof. The lowermost edgesof panel 16 engage inclined surfaces 27 and 28 which tend to align thepanel symmetrically within the rail. A framing strip 30,

. preferably made of wood, is cemented along the bottom of center panellayer 20 between outer layers 21 and 22 as shown and the bottom wall 26of floor rail 17 is secured to this strip 29 by a plurality oflongitudinally spaced screws 31. Thus floor rail 17 is permanentlysecured to panel 16.

The underside of rail 17 has laterally spaced longitudinally extendingside extensions 32 and 33 which define opposed inner slots 34 and 35,respectively, for slidably receiving and interlocking with tongues 18'of gripper plate 18. For wall installations on carpets C, plate 18 isformed with a plurality of downwardly extending integral prongs orprojections 37 which are adapted to penetrate the nap of the carpet andhold the module in a fixed position on the floor. Alternatively, foradapting the module for mounting on hard surface floors, the modifiedgripper plate 39, see FIG. 3, is provided with a plane pressuresensitive adhesive surface 40 projecting below side extensions 32 and 33of the floor rail 17 for engaging and adhering to the hard floorsurface. In other respects, gripper plates 18 and 39 are the same.

In order to finish the vertical side edges of the panel 16, verticallyextending framing strips 42 and 43, see FIGS. 4 and 5, preferably madeof wood, are cemented between and at the opposite outer edges of tackboard layers 21 and 22, and metallic end plates 44 and 45 are secured tostrips 42 and 43 respectively, by screws 46 or the like.

In accordance with this invention, the length L of gripper plate 18 (orplate 39) is substantially less than the length K of rail 17 so that thegripper plate is able to move longitudinally relative to the rail whileinterlocked with it. Screws 47 and 48 secured in opposite ends of railwall 26 after insertion of plate 18 in the rail project below wall 26and serve to limit such relative movement. When modules are assembled atthe factory and prior to delivery to the construction site, each gripperplate 18 preferably is positioned in the associated floor rail so as tobe equally spaced by a distance D from movement limiting screws 47 and48. The fit of plate 18 in rail slots 34 and 35 is sufficiently snug toprevent relative movement during transportation and handling. Thedistance D, is selected to be equal to or greater than the spacing Ddesired between adjacent modules to permit a workmans hand to becomfortably positioned therebetween while gripping the side edge 45 ofthe module being installed. By way of example, the spacing D may be 3inches and in such case the length I of gripper plate 18 would beapproximately 6 inches or more shorter than the length K of the rail;typically Kfl8 and L=42". Thus the space between modules shown in FIG. 4permits a workman to grasp the panel edge defined by end plate 45 as hepositions the module into the vertical plane of the intended wall; whenthe module is so positioned and gripper plate 18 frictionally engagesthe carpet, the entire module except for the gripper plate is moved tothe left as viewed into abutment with the adjacent module as shown inFIG. 5.

The module described above is symmetrical about its vertical center lineand therefore may be installed with either side edge facing the modulelast installed. By I prepositioning gripper plate 18 so as to be equallyspaced from screws 47 and 48 such versatility in installation isaccommodated. If the panel is not so symmetrical or if for other reasonsit must be installed with a prescribed edgewise orientation, plate 18obviously must be spaced by a distance D or greater from screw 47 remotefrom the previously installed module.

End module 14 may have the same width as the other modules or may benarrower as shown in FIG. 1 depending on the overall desired length ofthe wall. If the installed wall is to extend between the two side wallsS and S module 14 is cut to size of the opening either on site orpreferably at the factory and is installed in the conventional manner inthe remaining space, i.e., it is simply fitted snugly into the openingwith little or no longitudinal play.

In the modified wall construction shown in FIG. 6, provision is made forattaching appurtenances such as shelves, fixtures, etc. to the wall. Forthis purpose, the junction of preferably each module with another moduleor with the side wall has an elongated vertical post 50 with a generallyH-shaped cross-sectional configuration. Post 50 extends the height of apanel and com- .prises a pair of channel-shaped elongated bars 51 and 52secured together by securing means such as screws 53 in a directiontransversely of the plane of the wall panels. Alternatively, bolt 54 andnut 55 may be used. Each bar has a channel-shaped body 56 defining avertical slot 57 and having inwardly extending lips 58 at the outer endof the slot. Flanges 59 and 60 extend in opposite directions from theouter edges of the bar body 56 and define with the latter an innershoulder 61 adapted to engage a vertically extending edge of one of thewall panels 16. The outer ends of the flanges are formed withcontinuously inwardly projecting ribs 62 which may snugly engageadjacent parts of the panel.

In order to provide an anchor means for screws 53, an integrally formedweb 64 extends inwardly from body 56 of post bar 51 and has at its innerend an enlarged anchoring head 65 with a vertically extendingchannel-shaped recess 66 that is slightly narrower than the diameter ofthe screw 53. Head 65 is symmetrical about the center plane of bar 51and is formed on one side of web 64 as shown. A hole drilled in the backwall of bar 52 receives the screw which engages the sides of recess 66in head 65 in a self-tapping manner to draw the two bars together toform a unitary type post. The two bars 51 and 52 may be more positivelysecured together by substituting bolts 54 for the screws; each boltextending through the back wall of bar 52, through head 65 and throughthe back wall of bar 51 for engagement with nut 55 in slot 57. Such twopiece post construction permits the wall panels to be clamped in a tightgrip afforded by a plurality of vertically spaced screws 53 or bolts 54.

A module according to the invention comprises panel 16 having end plate77 nailed or otherwise secured to framing strip 78 along one panel sideedge and post 50 clamped to the other side edge. Plate 77 is formed witha trapezoidally shaped projection 77a and recess 77b and has shoulders80 and 81 for receiving ribs 62 of post flanges 59. Thus each junctionof adjacent modules has a post 50 in whose outer slot 57, for.

example, a bracket 83 may be connected as shown. In other respects,including floor rail and gripper plate, the module of FIG. 6 is the sameas the modules of FIG. 1.

In order to provide an effective interlock between side wall S and theadjacent module 75, an elongated vertically extending trapezoidallyshaped terminal plate 85 similar to module end plate 77 is secured towall S by a plurality of vertically spaced screws, one of which is shownat 86. A correspondingly though reversely shaped adapter plate 87 isfitted or clamped between post flanges 59 of the adjacent or firstmodule, and plates 85 and 87 abut each other as shown when the module ismoved into final position against the wall. Plate 87 may also be used toabut plate 77.

The final module 14' of the wall between side wall S and the lastcomplete module 75 corresponds to module 14 of FIG. 1 and comprises post50' clamped to panel 16 and post 50" clamped to an elongated verticallyextending terminal palte 89, the latter being secured to wall S, byscrews 90. Posts 50' and 50 are substantially identical to posts 50 andpanel 16' may be rough cut to size on the site to' fill in the remainingspace. Plate 89 has side walls 91 and 92 designed to be gripped by thepost flanges for completing the connection between the installed andpermanent walls.

The method of installing a modular wall in accordance with the inventionwill be better understood with reference to FIGS. 7, 8 and 9 in whichthe modules are designated by numbers indicating the order ofinstallation. A workman lifts module 1 by grasping both vertical edgesand telescoping its top edge into ceiling rail 11. The lower portion ofthe module is then swung into the vertical plane of the ceiling rail andis lowered to rest on the floor with the gripper plate 18 or 39frictionally engaging the floor covering and the module side edge spaceda distance D from side wall 8, sufficiently to provide clearance for theworkman 5 hand. The position of module at this point is shown in FIG. 7.Next the panel 16 and floor rail 17 of module 1 are moved longitudinallyover the floor into abutment with side wall S, and the gripper plateremains stationary as the floor rail slides over it.

These steps are repeated for installing module 2 which again is spaced adistance D from module 1 as shown in FIG. 8 prior to final longitudinalmovement into abutment with the adjacent side edge of module 1. Thisprocess is repeated for modules 3, 4 and 5, leaving a final openingbetween module 5 and side wall S which may be narrower than the width ofeach of the other modules as shown in FIG. 9. Whether narrower or not,the final opening is filled with module 6 cut to size on the site or atthe factory and installed as described above but without providing thespacing D.

In constructing a wall according to the FIG. 6 em bodiment terminalplate 85 is first secured to side wall 8,. The first preassembled module75 with adapter plate 87 added is then lifted into telescoping relationwith the ceiling rail, is swung into the vertical plane of the ceilingrail and is then lowered to rest on the floor with adapter plate 87spaced a distance D (FIG. 7) from the terminal plate 85. The gripperplate associated with the floor rail of module 75 is thus frictionallylocked to the floor covering. Panel 16 together with end plate 77, post50 and theassociated floor rail are then moved longitudinally as a unitover the floor (and gripper plate) until adapter plate 87 engages andinterlocks with terminal plate 85. This establishes a firm connectionbetween the side wall S, and the wall being installed. These steps arerepeated for successive modules until space for the final unit 14remains.

Terminal plate 89 is then connected to side wall S by screws 90 in thevertical plane of the wall being installed. Post 50 is next looselyassembled and positioned so that its flanges overlay the side walls ofterminal plate 89. Panel 16 of module 14 is then rough or saw-cut onsite to a width corresponding to the space between posts 50' and 50";this panel is then lifted into the ceiling rail and withinn the flangesof post 50", is rested on the floor, and post 50" is then tightened.Post 50 is next assembled and clamped on the exposed edge of panel 16and plate 77 of the adjacent module 75 to complete the installation.

Alternatively, final module 6, see FIG. 9, may be constructed to providelimited spring-loaded longitudinal movement between a minimum width Yand an expanded width Z. In this form, the final module is manuallycontracted while being installed in the plane of the wall and thereafteris permitted to expand under the force of its springs into the finalposition against side wall S In a similar vein, a spring-loaded terminalplate fastened to side wall S may be provided to expand and contract inthe plane of the wall to facilitate quick installation of the finalmodule.

What is claimed is:

l. The method of installing a modular wall compris ing a plurality ofmodules, each having a panel and a rail secured to the lower edge of thepanel and a gripper plate slidably interlocked with said rail,consisting of the steps of lifting said module into the vertical planeof the intended wall and in an intermediate position longitudinallyspaced from a final module position, lowering the module upon the floorwith the gripper plate frictionally engaging the floor covering,longitudinally moving the panel and rail portions of said module fromsaid intermediate position into said final position while said gripperplate remains stationary relative to said floor covering, and

repeating said steps for others of said modules.

1. The method of installing a modular wall comprising a plurality ofmodules, each having a panel and a rail secured to the lower edge of thepanel and a gripper plate slidably interlocked with said rail,consisting of the steps of lifting said module into the vertical planeof the intended wall and in an intermediate position longitudinallyspaced from a final module position, lowering the module upon the floorwith the gripper plate frictionally engaging the floor covering,longitudinally moving the panel and rail portions of said module fromsaid intermediate position into said final position while said gripperplate remains stationary relative to said floor covering, and repeatingsaid steps for others of said modules.